Mr. R. R. Diwanji Techniques for Safety Improvements
Dec 18, 2015
Mr. R. R. Diwanji
Techniques for Safety Improvements
Searching for hazards
Intuitive methods Inductive Methods
Key points check listsFailure mode and effect analysisDecision Table TechniqueIncident sequence AnalysisHazard and Operability Studies (HAZOP)Action Error Analysis
Deductive methods•The Fault Tree Techniques
• Developed by ICI
• Six Stages of Study
Study 1 - To identify the basic hazard of material and operation.
Study 2- To identify the significant hazard at the project definition stage and determine the appropriate design features.
Study 3- This is hazard & operability study (HAZOP). To identify hazards operability problems after project / plant is designed.
Hazard Study
Study 4- Before introduction of process material proper checks are introduced for the hazard identified in study 1 to 3.
Study 5- To check whether project meets company & Legislative requirements
Study 6- Performed after 3 - 6 months of continuous operation the checks introduced after hazard study 1 to 4 are properly functioning.
Hazard Study
How do I carry out HAZOP ?
•Assemble a team of min-3 and max 5 people
•Experts required fromProcessMaintenanceDesignR&DSafety
•Safety personnel acts as a study leader
•Focus on Guidewords
Guidewords
Key words Meaning Comments
NONOT
completefailure
Not even part of the intentions or functions is achieved.
MORELESS
increase orreduction
Can refer to quantities or qualities, e.g. throughput,temperature, as well as to functions like “heating “ or “reactwith”
AS WELL AS
PART OFSOME OF NOT
qualitative increase
qualitativedecrease
In addition to the intended function some unintended functionstakes placeOnly part of the intentions or functions are achieved.
REVERSE
OTHER THAN
the logical oppositeof the intention
completesubstitution
mostly applicable to functions (e.g. reverse flow, wrongsequence)
Intention or function is not achieved, something quite differenthappens.
HAZOP -A STEP by STEP APPROACH
1. Select a line from P& I diagram.2. Explain intention of the line.3. Apply first guideword.4. Develop meaningful deviation.5. Examine possible causes.6. Examine consequences.7. Detect the hazard.8. Make suitable record.9. Write corrective actions
POSSIBLE PARAMETERS
Flow Pressure Temp Mixing
Level Viscosity Phase Addition
Transfer Control Maintain Part. Size
PH Sequence Speed Signal
Time Start / stop
SUPPLY OF CHLORINE -Example
•Proposal- Supply of Chlorine gas from caustic soda plant to chlorination unit at M. C. B. Plant.
•Define Intention- To supply dry pure chlorine gas at 1 to 1.5kg/cm2 pressure at the rate of 200 to 250 5kg/hr. to chlorination unit at M.C.B. plant.
•Apply Guideword to - Dry, Pure, Pressure, Rate etc.
Application
• Mainly used for continuous plant operation.Eg. Distillation columns, Complex automatic Plants, Critical parts of the system
Advantages of HAZOP Study
• Structured process• Improves operability • Moderator supports systematic procedure.
Disadvantages of HAZOP Study
Higher time commitment (mainly for larger systems)
Considers Technical aspects mainly only normal operation but start up - shut down procedures
Assumes previous analysis of chemical process risks
RISK ANALYSIS & PROCESS SAFETY
• Developed by CIBA- Geigy for searching hazard using check list
•What is Hazard?
The possibility of undesirable event that could take place
•What is risk?
Evaluation of hazard in terms of probability & Severity
Sources of Hazard
Chemicals themselves
Chemical reactions
Energies used for the process
Installations (Equipments).
Sources of Deviation
Technical defects
Human Error
System Error
How do I carry out Risk Analysis?
I. Collection of Basic data Physical / Chemical / Toxicity / Reaction data.II. Safe condition / Limitations III. Systematic search for the hazard.IV. Analysis of hazard according to severity& probabilityV. Listing of Risks.VI. Suggesting measures.VII. Residual risk.
Sample Check List
1. Process conditions• What happens if wrong R.M. is charged?• What happens if sequence of R. M. is charged?• What happens if rate of R.M. charge increases or decreases?• What happens if temperature is high?• What happens if pressure increases etc?
2. Interruption in Utilities• Power Failure• Cooling Failure• Heating Failure• Nitrogen Failure
Application
Mainly to the batch process.
Auxiliary plants with manual operators
Checking of process.
Start up shut down procedures.
Advantages
Screening procedures
Relatively less time required for data collections.
Gives a first quick overview.
Disadvantages
Additional investigations may be required for data collections.
No fully developed check lists available for complex process.
Accident Investigation
Why accident investigation?- To determine the cause of accident and not to identify scape goat.- Uncovering problems that did not directly lead to the accident.- On going effort to reduce likely hood of accident.- Prevent similar accidents in future.
As soon as all emergency procedures have been completed.Reason being - More likely to get more accurate information.
-Information becomes fade in people’s mind. -Likelihood of accident scene may get changed. -Human nature encourages people to change their
stories with those of other witnesses.
When to investigate?
- Minor injury the supervisor of injured person - Team should be consist of - Plant I/C, - Safety personnel, - Maintenance man and- Immediate supervisor.
Who should investigate?
Root Cause analysis
There may be many reasons why an accident occurs.
Define Problem
Diagnose all Causes
Identify Solutions Implement
Review
Diagnose Symptoms
Identify Solutions
Define the problem / incident accurately Ask the question “WHY did the problem occur”? List down all possible causes as you brainstorm Keep asking a series of “WHY” for each cause until the
most fundamental cause is identified Event Tree or Fish bone techniques can be used to
pictorially represent all causes Highlight all root causes Prioritize them Implement actions to prevent recurrence of the root causes Fix the problem for ever
How a root Cause Analysis is done?
The analysis must be initiated within 24 hoursRoot Cause Analysis must be done by a teamAdequate Representation from various functions
Written Report to be preparedImmediate causes (symptoms) & Root (underlying) Causes to be identified
Action Plan to prevent recurrence to be prepared
Structure of RCA
a structured method to identify all possible causes of an
accident to seek a preventive solution
Advantages: